Location

Sanford, FL

Year Completed

2013

Sector

Buildings

Value

less than $10M

Market Type

Corporate Office

Services

CM-at-Risk

Multi-Phase Schedule Ensures Zero Down Time for Online Labels

Online Labels knew the renovation of a 170,000 square-foot industrial building to accommodate office and production space for the company’s new headquarters could be “sticky” business. The owner’s main concern for the project was finding a true Relentless Ally who could not only build a world-class facility but also move all of their existing product machinery that ran 24/7 to the new facility with no lost production time.

The project, delivered using a design-build delivery method, was executed in three, fast-track phases. The first phase included critical coordination and finalization of the factory area layout and MEP design. The second phase was the renovation portion consisting of coordination and implementation of the demolition work within the existing building. The final phase required a substantial completion of work to enable the phasing of the owner’s equipment installation. This critical need was accomplished through a team approach including all project partners and the City of Sanford Building Department who were able to provide inspection services outside of its normal operating hours. Built to make the owner’s vision and expectations a reality, the Balfour Beatty project team was able to consistently deliver each phase meeting all deadlines to make sure the new Online Labels Headquarters was a success.

In this heavy design/build renovation to an existing fortified defense contractor facility, the team was required to think on-the-fly to successfully deliver each phase.

During a portion of the demolition phase, the team came across a challenging condition in the existing gang bathrooms in the back of the facility. In this specific area, demolition of the existing masonry walls was required in order to rework the plumbing lines behind the walls to make the bathrooms ADA compliant. It was soon realized that cutting into the walls would compromise the structural integrity of them as well as the full weight storage area slab above. The team redesigned the entire area and achieved the following results: (1) new plumbing chase with framed walls, (2) expanded the men’s room within the space, (3) moved the women’s room partially into an adjacent space that achieved the design intent with even more functionality.

Adding this unforeseen work to the already tight project schedule jeopardized the substantial completion date. This change required close coordination with the demolition, framing, plumbing, fire protection and electrical subcontractors as all of these trades were affected by the removal of the walls and ceilings. Balfour Beatty and the subcontractors created a solution together that maintained the integrity of the critical path by requiring a combination of trade stacking and overtime work. In the end, the additional work was managed successfully and avoided any schedule delays pertaining to the buildings completion and grand opening.